Brake Master Cylinder Sub-ASSY: Overhaul

1. Disconnect the brake fluid level switch connector from the master cylinder reservoir sub-assy.
2. M/T: Slide the clip and disconnect the clutch reservoir tube No.1 .
3. Using SST, disconnect the 2 brake tubes from the master cylinder.

   SST 09023-00100

   Fig 1: Disconnecting Brake Tubes From Master Cylinder Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, disconnect the 2 or 3 brake tubes from the No.1 way.

   SST 09023-00100

   Fig 2: Disconnecting 2 Or 3 Brake Tubes From No.1 Way

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 nuts, pull out the master cylinder, No.1 way, and check valve bracket.
   Fig 3: Removing Master Cylinder Sub-Assy And No.1 Way

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reservoir stopper screw and master cylinder reservoir sub-assy.
2. Remove the 2 cylinder reservoir grommets.

1. Hold the master cylinder in a vise with the 2 aluminum plates in between.
2. Remove the O-ring.
3. Push in the piston and remove the snap ring using snap ring pliers.
   NOTE: When pushing in the piston, the fluid left in the cylinder may spatter.
   Fig 4: Removing O-Ring From Master Cylinder Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Push in the piston and remove the piston stopper bolt and gasket.
   Fig 5: Pushing In Piston And Removing Piston Stopper Bolt And Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the No. 1 piston sub-assy by hand, pulling straight out not at an angle.
   NOTE: If being pulled out at an angle, the piston may damage the cylinder bore.
6. Place a cloth and 2 wooden blocks on the work table and lightly edges until the No. 2 piston sub-assy drops out of the cylinder.

Fig 6: Pulling Out No. 2 Piston Straight From Master Cylinder Body

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the cylinder bore for rust or scoring.

1. Hold the master cylinder in the vise with 2 aluminum plates in between.
2. Apply lithium soap base glycol grease to the No. 1 and No. 2 piston sub-assy.
3. Install the No.2 and No.1 piston sub- assy to the master cylinder.
   NOTE:

   • If being inserted at an angle, the piston may damage the cylinder bore.
   • Be careful no to damage the rubber lips on the pistons.
4. Push in the piston and install a new gasket and a new piston stopper bolt.

   Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

   Fig 7: Pushing In Piston And Installing New Gasket And New Piston Stopper Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Push in the piston and install the snap ring with snap ring pliers.
   Fig 8: Pushing In Piston And Removing Piston Stopper Bolt And Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the straight pin is installed correctly.
6. Apply the lithium soap base glycol grease to a new O-ring, and install the O-ring to the master cylinder.

1. Apply lithium soap base glycol grease to the 2 master cylinder reservoir grommets.
2. Install the master cylinder reservoir with the screw.

1. Apply chalk to the flat surfaced tip of the SST pin.

   Clearance: -0.21 to 0 mm (-0.0083 to 0 in.) 

2. Set SST on the master cylinder and lower the pin of the SST until it slightly touches the piston.

   SST 09737-00013

   Fig 9: Inspecting Brake Booster Push Rod

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn SST upside down and place it on the brake booster.

   SST 09737-00013

   Hint:

   If there is a space between the SST main body and the booster shell (chalk is applied to the booster push rod, it means the clearance is too small. If chalk is not applied to the booster push rod after placing the SST on the brake booster, it means that the clearance is too large.

4. If the clearance is outside of the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt.

   SST 09737-00020

   Hint:

   When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

   Fig 10: Adjusting Brake Booster Push Rod Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the master cylinder sub-assy and No.1 way, and vacuum check valve bracket with the 2 nuts.

   Torque: 12.5 N.m (127 kgf.cm, 9 ft-lbf) 

   Fig 11: Installing Master Cylinder Sub-Assy And No.1 Way, And Check Valve Bracket With Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, connect the 2 or 3 brake tubes to the No.1 way.

   SST 09023-00100

   Torque: 15.2 N.m (155 kgf.cm, 11 ft.lbf) 

   Fig 12: Connecting 2 Or 3 Brake Tubes To No.1 Way

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, connect the 2 brake tubes to the master cylinder sub-assy.

   SST 09023-00100

   Torque: 15.2 N.m (155 kgf.cm, 11 ft.lbf) 

4. M/T: Connect the clutch reservoir tube No.1 with the clip to the master cylinder reservoir sub-assy with the clip.
5. Connect the brake fluid level switch connector to the master cylinder reservoir sub-assy.
   Fig 13: Connecting Brake Tubes To Master Cylinder Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09023-00100